It is of vital importance, before attempting to operate your engine, to read the general 'SAFETY INSTRUCTIONS AND WARNINGS' section on pages 2-6 of this booklet and to strictly adhere to the advice contained therein. q Also, please study the entire contents of this instruction manual, so as to familiarize yourself with the controls and other features of the engine. q Keep these instructions in a safe place so that you may readily refer to them whenever necessary. It is suggested that any instructions supplied with the aircraft, radio control equipment, etc., are accessible for checking at the same time. q CONTENTS SAFETY INSTRUCTIONS AND WARNINGS ABOUT YOUR O.S. ENGINE INTRODUCTION INSTALLATION OF THE ENGINE INSTALLATION OF SILENCER NEEDLE-VALVE LOCATION BEFORE STARTING ADVICE ON SELECTION OF FUEL, GLOW PLUG & PROPELLER STARTING THE ENGINE RUNNING-IN (Breaking-in) CARBURETTOR 2~6 7 8 9 10 10~12 12~14 14~22 23 CARBURETTOR EXPLODED VIEW & PARTS LIST THREE VIEW DRAWING 36 37~38 CARBURETTOR AIR-BLEED ADJUSTMENT TROUBLE SHOOTING WHEN THE ENGINE FAILS TO START CARE AND MAINTENANCE OPTIONAL PARTS & ACCESSORIES ENGINE EXPLODED VIEW & PARTS LIST 23~24 25 26~27 28 29 30~35 1 SAFETY INSTRUCTIONS AND WARNINGS ABOUT YOUR O.S. ENGINE Remember that your engine is not a "toy", but a highly efficient internalcombustion machine whose power is capable of harming you, or others, if it is misused. As owner, you, alone, are responsible for the safe operation of your engine, so act with discretion and care at all times. If at some future date, your O.S. engine is acquired by another person, we would respectfully request that these instructions are also passed on to its new owner. The advice which follows is grouped under two headings according to the degree of damage or danger which might arise through misuse or neglect. WARNINGS These cover events which might involve serious (in extreme circumstances, even fatal) injury. 2 NOTES These cover the many other possibilities, generally less obvious sources of danger, but which, under certain circumstances, may also cause damage or injury. WARNINGS · Never touch, or allow any object to come into contact with, the rotating propeller and do not crouch over the engine when it is running. · Model engine fuel is also highly flammable. Keep it away from open flame, excessive heat, sources of sparks, or anything else which might ignite it. Do not smoke or allow anyone else to smoke, near to it. ·A weakened or loose propeller may disintegrate or be thrown off and, since propeller tip speeds with powerful engines may exceed 600 feet(180 metres) per second, it will be understood that such a failure could result in serious injury, (see 'NOTES' section relating to propeller safety). allow it to come into contact with the eyes or mouth. Always store it in a clearly marked container and out of the reach of children. 3 · Never operate your engine in an enclosed space. Model engines, like automobile engines, exhaust deadly carbonmonoxide. Run your engine only in an open area. · Model engines generate considerable heat. Do not touch any part of your engine until it has cooled. Contact with the muffler (silencer), cylinder head or exhaust header pipe, in particular, may result in a serious burn. · Model engine fuel is poisonous. Do not NOTES · This engine was designed for model aircraft. Do not attempt to use it for any other purpose. · If you remove the glowplug from the engine and check its condition by connecting the battery leads to it, do not hold the plug with bare fingers.Use an appropriate tool or a folded piece of cloth. · Mount the engine in your model securely, following the manufacturers' recommendations, using appropriate screws and locknuts. sure to use the silencer (muffler) supplied with the engine. Frequent exposure to an open exhaust may eventually impair your hearing. Such noise is also likely to cause annoyance to others over a wide area. · Fit · Be a top-quality propeller of the diameter and pitch specified for the engine and aircraft. Locate the propeller on the shaft so that the curved face of the blades faces forward-i.e. in the direction of flight. Firmly tighten the propeller nut, using the correct size wrench. 4 NOTES · Always check the tightness of the propeller nut and retighten it, if necessary, before restarting the engine, particularly in the case of four-stroke-cycle engines. If a safety locknut assembly is provided with your engine, always use it. This will prevent the propeller from flying off in the event of a "backfire", even if it loosens. If you fit a spinner, make sure that it is a precision made product and that the slots for the propeller blades do not cut into the blade roots and weaken them. use an electric starter. The wearing of safety glasses is also strongly recommended. · Discard any propeller which has become split, cracked, nicked or otherwise rendered unsafe. Never attempt to repair such a propeller: destroy it. Do not modify a propeller in any way, unless you are highly experienced in tuning propellers for specialized competition work such as pylon-racing. · Take care that the glow plug clip or battery leads do not come into contact with the propeller. Also check the linkage to the throttle arm. A disconnected linkage could also foul the propeller. · · Preferably, · After starting the engine, carry out any needle-valve readjustments from a safe position behind the rotating propeller. Stop the engine before attempting to make other adjustments to the carburettor. 5 NOTES · Adjust the throttle linkage so that the engine stops when the throttle stick and trim lever on the transmitter are fully retarded. Alternatively, the engine may be stopped by cutting off the fuel supply. Never try to stop the engine physically. · For · Take care that loose clothing (ties, shirt sleeves, scarves, etc.)do not come into contact with the propeller.Do not carry loose objects (such as pencils, screwdrivers, etc.) in a shirt pocket from where they could fall through the propeller arc. their safety, keep all onlookers (especially small children) well back (at least 20 feet or 6 meters) when preparing your model for flight. If you have to carry the model to the take-off point with the engine running, be especially cautious. Keep the propeller pointed away from you and walk well clear of spectators. Immediately after a glowplugignition engine has been run and is still warm, conditions sometimes exist whereby it is just possible for the engine to abruptly restart if the propeller is casually flipped over compression WITHOUT the glowplug battery being reconnected. Remember this if you wish to avoid the risk of a painfully rapped knuckle! · Warning! · Do not start your engine in an area containing loose gravel or sand. The propeller may throw such material in your face and eyes and cause injury. 6 INTRODUCTION THE MAX-40LA, 46LA and 65LA have been developed to meet the requirements of beginners and sport flyers. Of modern design and having a separate needle-valve unit mounted at the rear, where manual adjustment is safely remote from the rotating propeller, they offer the advantages of reliability and easy handling, at lower cost. Like all O.S. engines they are built to standards of engineering excellence that have evolved through more than 60 years' experience in the design and production of model internal-combustion engines. Advanced modern precision machinery, top quality materials and the efforts of highly skilled craftsmen and technicians are combined to ensure a continuation of the levels of performance, durability and reliability for which O.S. is world famous. The MAX-46LA has a larger cylinder diameter, but both the 40LA and 46LA engines have the same external dimensions. The 'midnight blue' external finish may be decolorized by very high surface temperature or by certain solvents. Such decolorization does not affect engine perfor-mance, however. Cylinder head Glowplug Needle valve Carburettor Fuel outlet Propeller nut Cover Plate Fuel inlet Drive Hub Crankshaft Propeller washer Crankcase Silicone Tube Connect the short length of fuel tubing supplied securely between the fuel outlet and the fuel inlet. In the event of the tube becoming damaged, it should be replaced with a suitable length of best quality 5mm ODX2mm ID silicone tubing. Use similar material to connect the fuel inlet nipple to the fuel tank. 7 INSTALLATION Installation in the model A typical method of beam mounting is shown below,left. O.S. radial motor mount (Available as an optional extra part. See parts list) How to fasten the mounting screws. 3mm steel nuts (40-46LA) 4mm(65LA) Spring washer or lock washer Tighten second nut firmly down onto first nut. Tighten this nut first. Hardwood such as cherry or maple. Steel washer At least 12mm(1/2") At least 12mm(1/2")40-46LA 15mm(5/8")65LA Rigid hardwood (e.g. maple) 3.5mm steel screw (40-46LA) 4mm(65LA) Make sure that the mounting beams are parallel and that their top surfaces are in the same plane. CORRECT INCORRECT Hardwood mounting beams 3mm steel Allen screw Spring washer Front view Side view Top surfaces are not in the same plane. Re-align the surfaces as necessary Opposite beam Top surfaces are not in the same plane. Engine does not seat firmly. Top surfaces are in the same plane. O.S. radial motor mount (cast aluminum) 8 NEEDLE-VALVE EXTENSION The needle-valve supplied with these engines is designed to incorporate an extension so that, when the engine is enclosed within the fuselage, the needle-valve may be adjusted from the outside. Cut a commercially available rod to the required length, bend one end to an L shape, insert it into needle's center hole and secure it by tightening the set-screw in the needle-valve knob with 1.5mm. Allen key. Assembly screw Cone baffle Turn to requlred position Exhaust outlet Exhaust pressure nipple Locknut INSTALLATION OF SILENCER The angled exhaust of the silencer can be rotated to any desired position in the following manner: 1) Loosen the locknut and assembly screw. 2) Set the exhaust outlet at the required position by rotating the rear part of the silencer. 3) Re-tighten the assembly screw, followed by the locknut. The standard silencer is quite effective but reduces power to some degree. Reminder! Model engines generate considerable heat. Do not touch any part of your engine until it has cooled. Contact with the muffler (silencer), cylinder head or exhaust header pipe, in particular, may result in a serious burn. NEEDLE-VALVE LOCATION As delivered from the factory, the MAX-40LA, 46LA & 65LA have the needle-valve assembly installed vertically. However, if more convenient for a particular installation, the needle-valve may be reinstalled horizontally. The procedure for relocating the needle-valve is as follows: 9 1. Remove the two cover-plate screws which secure the needle-valve assembly bracket, then carefully remove the two screws by which the needle-valve unit is attached to the bracket. 2. Rotate the needle-valve unit through 90° and reattach it to the bracket in the required position (see sketch right ). Note: As self-tapping screws are used for unit attachment, screw them in carefully so that screw threads match those of the unit body precisely. 3. Finally, secure the complete assembly to rear cover plate as before. BEFORE STARTING Tools, accessories, etc. The following items are necessary for operating the engine. 1 Fuel Model glowplug engine fuel of good quality, preferably containing a small percentage of nitromethane. (See "Advice on selection of fuel, glowplug and propeller") 2 Glowplug O.S. A3 glowplug is installed in the engine. 3 Propeller Suggested size is 11X5 (40LA), 11X6 (46LA), or 12X6 (65LA). 4 Glowplug battery The power source for heating the glowplug may be either a large heavy-duty 1.5volt dry cell, or preferably, a 2-volt rechargeable lead-acid cell (accumulator). If a 2-volt cell is employed, use a resistance wire, as shown, to reduce applied voltage, otherwise the element will overheat and burn out. 1.5 volt heavy-duty or 2 volt rechargeable dry battery lead-acid cell (at least 5Ah) Needle Valve unit Cover plate fitting holes Needle-Valve Assembly Bracket Vertical position (Factory position) Horizontal position Needle Valve unit attachment screws 10 Warning (Very hot) Never touch the nichrome wire while the battery is connected. Resistance coil (nichrome wire) to ge ss. e olta er v ightn Low uce br red e Raisage to volt ease . cr tness in h brig Battery leads Adjust applied voltage by changing the position of clip on resistance coil until glowplug element is glowing bright red. 5 Plug wrench Used for tightening glowplug. The O.S. long plug wrench is available as an optional accessory. 6 Battery leads These are used to conduct current from the battery to the glowplug. Basically, two leads, with clips, are required, but, for greater ...